Dirt collection chamber for a surface cleaning apparatus

ABSTRACT

A surface cleaning apparatus comprises an air flow path extending from a dirty air inlet to a clean air outlet. A suction motor may be provided in the air flow path. A cyclone chamber may be provided in the air flow path. The cyclone chamber may comprise a cyclone air inlet, a cyclone air outlet and a cyclone dirt outlet. A dirt collection chamber may comprise a dirt inlet in communication with the cyclone dirt outlet, an annular portion that surrounds at least a portion of the cyclone chamber, an inner side adjacent the cyclone chamber, and an outer side spaced from the cyclone chamber and defined by a dirt collection chamber sidewall. A support surface may extend between the inner side and the outer side. The support surface may extending part way around the annular portion and may extend away from the dirt inlet.

FIELD

The disclosure relates to surface cleaning apparatuses, such as vacuum cleaners.

INTRODUCTION

Various constructions for surface cleaning apparatuses, such as vacuum cleaners, are known. Currently, many surface cleaning apparatuses are constructed using at least one cyclonic cleaning stage. Air is drawn into the vacuum cleaners through a dirty air inlet and conveyed to a cyclone inlet. The rotation of the air in the cyclone results in some of the particulate matter in the airflow stream being disentrained from the airflow stream. This material is then collected in a dirt bin collection chamber, which may be at the bottom of the cyclone or in a direct collection chamber exterior to the cyclone chamber (see for example WO2009/026709 and U.S. Pat. No. 5,078,761). One or more additional cyclonic cleaning stages and/or filters may be positioned downstream from the cyclone.

SUMMARY

The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.

According to one broad aspect, a surface cleaning apparatus comprises a cyclone chamber at least partially located within a dirt collection chamber such that at least a portion of the sidewall of the cyclone chamber is spaced from the sidewall of the dirt collection chamber to define a space therebetween in communication with the dirt outlet of the cyclone chamber. Preferably, the space is an annular region such that the sidewall of the dirt collection chamber extends all the way around the sidewall of the cyclone chamber. A support surface extends between the sidewall of the dirt collection chamber extends and the sidewall of the cyclone chamber. The support surface is configured to direct dirt towards the dirt collection area of the dirt collection chamber.

The cyclone chamber may have a generally circular sidewall, and a generally annular gap can be formed between the cyclone chamber sidewall and a surrounding dirt collection chamber sidewall. The supporting surface may comprise at least one declined or ramp surface extending away from the cyclone chamber dirt outlet, to help prevent dirt particles from being retained on the support surface.

An advantage of this configuration is that dirt particles may be more likely to fall into a lower portion of the dirt collection chamber, and may be less likely to be retained on the support surface. This may help facilitate emptying of the dirt collection chamber when a floor of the dirt collection chamber is opened.

Preferably, the dirt collection chamber has a dirt collection surface that is opposed to and faces the end of the cyclone chamber opposed to the end of the cyclone chamber having the dirt outlet (e.g., the dirt collection surface may be below the cyclone chamber). Accordingly, the annular region of the dirt collection chamber may function as a passage from the cyclone dirt outlet to the dirt collection surface. If dirt particles collect on the support surface, then those particles may be re-entrained in air flowing in the annular region.

A further advantage of this configuration is that the amount of dirt particles that collect on the support surface may be reduced and the amount of dirt particles re-entrained in the air stream returning to the cyclone chamber may be reduced, thereby increasing the separation efficiency of the cyclone chamber and dirt collection chamber.

In accordance with this broad aspect, a surface cleaning apparatus comprises an air flow path extending from a dirty air inlet to a clean air outlet. A suction motor may be provided in the air flow path. A cyclone chamber may be provided in the air flow path. The cyclone chamber may comprise a cyclone air inlet, a cyclone air outlet, a cyclone dirt outlet and a cyclone chamber wall. A dirt collection chamber may comprise a first end, a spaced apart opposed second end, a dirt inlet in communication with the cyclone dirt outlet, an annular portion that surrounds at least a portion of the cyclone chamber, an inner side adjacent the cyclone chamber, and an outer side spaced from the cyclone chamber and defined by a dirt collection chamber sidewall. A support surface may extend between the inner side and the outer side. The support surface may extend between the inner side and the outer side, and may be configured to direct dirt towards a dirt collection area of the dirt collection chamber.

The support surface may extending part way around the annular portion and may extend away from the dirt inlet.

The support surface may have first and second ends that are angularly spaced apart around the cyclone chamber. The support surface may extend continuously away from the dirt inlet from the first end to the second end.

The support surface may have first and second ends that are angularly spaced apart around the cyclone chamber and a mid-section. The support surface may extend continuously away from the dirt inlet from the mid-section to the first end and to the second end.

The support surface may be curved and may have first and second ends that are angularly spaced apart around the cyclone chamber. The support surface may extend towards the dirt inlet from the first and second ends at an angle of up to 50° from a plane transverse to a longitudinal axis of the cyclone chamber.

The support surface may extend towards the dirt inlet from the first and second ends at an angle from to 15° to 35° from a plane transverse to a longitudinal axis of the cyclone chamber.

The dirt inlet may be provided at the first end and the support surface may spaced from the dirt inlet towards the opposed second end.

The cyclone dirt outlet may be the dirt collection chamber dirt inlet.

The dirt collection chamber may comprise a dirt collection area that is provided at the opposed second end.

The dirt inlet may be at an upper end of the dirt collection chamber and the dirt collection area is in a lower portion of the dirt collection chamber.

The cyclone chamber and the dirt collection chamber may be provided in a cyclone bin assembly and the cyclone bin assembly is removably mounted to the surface cleaning apparatus.

The cyclone chamber may have a cyclone chamber first end and an opposed cyclone chamber second end and the cyclone dirt outlet is provided adjacent the cyclone chamber first end and the cyclone air inlet is provided at the opposed cyclone chamber second end.

The cyclone chamber air outlet may be provided at the opposed cyclone chamber second end.

The cyclone chamber first end may be an upper end of the cyclone chamber.

The cyclone chamber first end may be provided proximate the first end of the dirt collection chamber.

The cyclone chamber may have a cyclone chamber first end and an opposed cyclone chamber second end. The cyclone chamber may be provided proximate the first end of the dirt collection chamber. The opposed second end of the dirt collection chamber may be spaced from and may face the opposed cyclone chamber second end.

Air may travel in the annular portion in a direction of rotation and the support surface may extend away from the dirt inlet in the direction of rotation.

The support surface may have first and second ends that are angularly spaced apart around the cyclone chamber. The support surface may extend continuously away from the dirt inlet from the first end to the second end.

DRAWINGS

Reference is made in the detailed description to the accompanying drawings, in which:

FIG. 1 is a perspective view of a surface cleaning apparatus;

FIG. 2 is a perspective view of a cyclone bin assembly with the lid and floor removed;

FIG. 3 is a perspective sectional view taken along line 3-3 in FIG. 2; and,

FIG. 4 is a partial cut away view of the cyclone bin assembly of FIG. 2.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment of a surface cleaning apparatus 100 is shown. In the embodiment illustrated, the surface cleaning apparatus 100 is an upright surface cleaning apparatus. In alternate embodiments, the surface cleaning apparatus may be another suitable type of surface cleaning apparatus, including, for example, a hand vacuum, a canister vacuum cleaner, a stick vac, a wet-dry vacuum cleaner and a carpet extractor.

As exemplified in FIG. 1, the surface cleaning apparatus 100 includes a surface cleaning head 102 and an upper section 104. The surface cleaning head 102 includes a pair of rear wheels 106 and a pair of front wheels (not shown) for rolling across a surface and a dirty air inlet 108. The upper section 104 is moveably connected to the surface cleaning head 102. The upper section 104 is moveable (e.g., pivotally mounted) between a storage position and an in use position. An air flow passage extends from the dirty air inlet 108 to a clean air outlet 110 on the upper section 104. A handle 116 is provided on the upper section 104 for manipulating the surface cleaning apparatus 100.

As exemplified in FIGS. 1 and 2, the upper section 104 comprises an air treatment housing 112 and a suction motor housing 114. The air treatment housing 112 houses an air treatment member comprising at least one cyclone chamber and at least one dirt collection chamber, which is positioned in the air flow passage downstream from the dirty air inlet 108 to remove dirt particles and other debris from the air flowing through the air flow passage. In the illustrated example, the air treatment member comprises a cyclone bin assembly 118 comprising a cyclone chamber 120 and a dirt collection chamber 122. The suction motor housing 114 is configured to house a suction motor (not shown). The suction motor is in air flow communication with the air flow passage, preferably downstream from the cyclone bin assembly 118.

As exemplified, the cyclone bin assembly 118 is oriented vertically and the cyclone dirt outlet is provided at the upper end of the cyclone chamber 120. It will be appreciated that the cyclone bin assembly may be in other orientations when mounted to a surface cleaning apparatus and when in use.

The cyclone chamber 120 is bounded by a sidewall 124, a first (e.g., upper) end wall 124 and a second end wall 126, (e.g., a floor). Preferably, as exemplified in FIGS. 2-4, the cyclone chamber 120 is an inverted cyclone chamber. Accordingly, the dirt outlet is provided above the cyclone air inlet

Preferably, as exemplified, the dirt outlet end of the cyclone chamber 120 is openable. Accordingly, a lid 128 may cover the top of the cyclone chamber 120, and an inner surface of the lid 128 may comprise the first end wall 124 of the cyclone chamber 120. Preferably, the lid 128 is openable. Opening the lid 128 may allow a user to access the interior of the cyclone chamber 120, for example for cleaning. In the illustrated example, the lid 128 is pivotally connected to the cyclone bin assembly 118 by a hinge 132, and is movable between a closed configuration and an open configuration. The lid 128 can be held in the closed position by, e.g., a releasable latch 134. A handle 136 is provided on the lid 128. The handle 136 can be used to manipulate the cyclone bin assembly 118 when it is detached from the upper section 104. Other methods of moveably mounting or removably mounting the lid 128 may be used.

Preferably, the cyclone air inlet comprises a tangential air inlet. Preferably, as exemplified, tangential air inlet 138 is provided in the sidewall 124 of the cyclone chamber 120 and is in fluid communication with the dirty air inlet 108. Air flowing into the cyclone chamber via the air inlet can circulate around the interior of the cyclone chamber 120 and dirt particles and other debris can become disentrained from the circulating air.

Preferably, the dirt outlet 158 comprises a gap provided between the sidewall 124 of the cyclone chamber and first (upper) end wall 126. The gap may extend part way or all the way around sidewall 124. Preferably, as exemplified, the dirt outlet comprises a slot that extends part way around sidewall 122 between the end of sidewall 124 facing first end wall 126 and first end wall 126. Debris separated from the air flow in the cyclone chamber 120 can travel from the cyclone chamber 120, through the dirt outlet 158 to the dirt collection chamber 122.

Air can exit the cyclone chamber via an air outlet 140. In the exemplified embodiment, the cyclone chamber 120 is inverted and the dirt collection chamber includes a portion spaced from and facing the air outlet end of the cyclone chamber. Accordingly, the air exit conduit extends at least part way through the dirt collection chamber. For example, reference may be made to FIG. 2 and FIG. 4 in which the lower portion 168 of the dirt collection chamber 122 positioned beneath the cyclone chamber 120 has been removed. As exemplified, the cyclone air outlet includes a vortex finder 142 extending into the cyclone chamber 120. Optionally, a screen can be positioned over the vortex finder. In some embodiments, the screen and vortex finder 142 can be removable.

A down duct 144 extends from the vortex finder linearly through the lower portion 168 of the dirt collection chamber 122. The down duct 144 comprises a generally cylindrical duct member and may extend in any direction through the interior of the dirt collection chamber 122. Optionally, the down duct 144 can be detachable from the second endwall 128.

The cyclone chamber 120 extends along a longitudinal cyclone axis 146. In the example illustrated, the longitudinal cyclone axis 146 is aligned with the orientation of the vortex finder 142.

The dirt collection chamber 122 comprises a sidewall 148, a first (upper) end wall 150 and an opposing second end wall, or floor 152. The first end walls of the cyclone chamber and the dirt collection chamber may be configured to be openable concurrently, e.g., they may be integrally formed. Alternately, or in addition, the second end walls of the cyclone chamber and the dirt collection chamber may be configured to be openable concurrently, e.g., they may be integrally formed.

As exemplified, the floor 152 of the dirt collection chamber 122 is openable. Opening the dirt collection chamber floor 152 may help facilitate emptying dirt and other debris from the dirt collection chamber 122. In the example illustrated, the dirt collection chamber floor 152 is pivotally connected to the dirt collection chamber sidewall 148 by hinge, and is pivotable between and open position and a closed position. The dirt collection floor 152 also comprises an air outlet aperture that allows air from the down duct to pass through the floor 152. Optionally, sealing gaskets, or other sealing members, can be provided around the perimeter of the floor 152 and around the air outlet aperture, to help seal the dirt collection chamber 122 when the floor 152 is closed.

As exemplified, the dirt collection chamber has a portion adjacent the cyclone dirt outlet 158 that is preferably annular in shape (e.g., the upper annular portion) and a second spaced apart portion extending across the outer surface of the air exit end of the cyclone chamber (lower portion 168). Preferably, the portions are contiguous.

The dirt collection chamber 122 has a dirt collection chamber dirt inlet that is in communication with the cyclone dirt outlet 158. Preferably, the dirt inlet 153 is the dirt outlet 158 of the cyclone chamber 120.

In the illustrated example, the cyclone chamber 120 is nested towards the rear of the dirt collection chamber 122 (relative to the direction of travel of the surface cleaning apparatus 100), and a generally annular space 160 is defined between the cyclone chamber sidewall 124 and the dirt collection chamber sidewall 148. The annular space may have a constant width or the width may vary. Further, the annular space may surround the entire height of the cyclone chamber 120 or part thereof.

A support surface can be provided to help support the cyclone chamber 120. In the illustrated example, the support surface comprises a connecting wall 162 that is provided in the annular space 160 between the cyclone chamber sidewall 124 and the dirt collection chamber sidewall 148, rearward of the cyclone chamber 120. Connecting wall 162 surrounds a portion of the cyclone chamber 120, and in the illustrated example surrounds approximately 50% of the cyclone chamber 120.

In use, a portion of the dirty air in the cyclone chamber 120 may flow out of the dirt outlet 158 and circulate within the dirt collection chamber 122 in a rotation direction, as illustrated using arrows 164. A portion of this air may flow through the annular space 160 behind the cyclone chamber 120. Dirt particles entrained with the air circulating through annular space 160 can become disentrained from the air flow and may settle on the upper surface 166 of the connecting wall 162.

Preferably, the connecting wall 162 is configured to help shed the dirt particles that settle on the connecting wall 162, and to urge the dirt particles toward the lower portion 168 of the dirt collection chamber 122. Guiding the dirt particles toward the lower portion 168 of the dirt collection chamber 122 may help facilitate the collection of dirt and debris in the lower portion 168 of the dirt collection chamber 122, which may help facilitate emptying of the dirt collection chamber 122. It may also help prevent dirt particles from being retained on the upper surface 166 of the connecting wall 162. Preferably, the connecting wall 162 does not comprise flat surfaces that may retain dirt particles.

In the illustrated example, the connecting wall 162 has a high point 174 adjacent the tangential air inlet 138 that is at a higher elevation than the first and second ends 170, 172, thereby forming first and second ramp surfaces 178, 180. In this configuration, the high point 174 of the connecting wall is intermediate the first and second ends 170, 172, and is offset relative to a centre line cyclone chamber 176. Alternatively, the high point 174 of the connecting wall 162 can be aligned with the centre line 176. First and second ramp surfaces 178, 180 slope generally downwardly from the high point 174 toward the first and second ends 170, 172, respectively. In this configuration, the first and second ends 170, 172 are positioned at the points of lowest elevation on the connecting wall 162. Providing inclined ramp surfaces 178, 180 may help urge dirt particles settling on the ramp surfaces 178, 180 to move toward the corresponding ends 170, 172 of the connecting wall 162, and fall into lower portion of the dirt collection chamber 122.

The first ramp surface 178 is preferably a generally smooth surface extending from the high point 174 to the first end 170. The second ramp surface 180 may comprise a portion of the tangential air inlet sidewall 182 and comprises a kinked region 184 where the air inlet sidewall 182 joins with the connecting wall 162. Providing a kinked region 184, or other type of discontinuity in the ramp surface 180, may introduce eddy currents or other flow disturbances in the dirty air flow circulating within the annular space 160. Introducing disturbances in the air flow may help disentrain dirt particles from the air flow.

Optionally, instead of positioning the high point 174 of the connection wall intermediate the first and second ends 170, 172, the high point 174 can be positioned at one of the ends 170, 172 of the connecting wall 162. For example, the connecting wall 162 can be configured so that the first end 170 is the point of highest elevation 174 and the second end 172 is the point of lowest elevation, so that the connecting wall 162 may slope generally downward from the first end 170 to the second end 172, or vice versa. Preferably, at least one of the ends 170, 172 of the connecting wall is positioned at the point of lowest elevation of the connecting wall 162. Positioning at least one of the ends 170, 172 at the point of lowest elevation may help prevent low points or recesses along the length of the connecting wall 162, which may trap dirt particles, from being formed between the high point 174 and the ends 170, 172 of the connecting wall.

The ramp surface may be sloped or declined at an angle between about 5 degrees to about 80° relative to a plane that is perpendicular to the cyclone axis 146 (for example a horizontal plane), preferably between about 5 and about 50° and more preferably between about 15 and about 35°. The slope of the ramped surfaces 178, 180 is preferably generally constant along their length. However, the slope of the ramped surfaces 178, 180 may vary along the lengths of the surfaces 178, 180, so that a given ramped surface 178 or 180 can comprise relatively steeper and relatively flatter portions.

In the example illustrated, a portion of the connecting wall 162 is integral with the tangential air inlet sidewall 182. Alternatively, the tangential air inlet sidewall 182 can be separate from the connecting wall 162 and may not pass through the dirt collection chamber 120.

What has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. 

1. A surface cleaning apparatus comprising: (a) an air flow path extending from a dirty air inlet to a clean air outlet and including a suction motor; (b) a cyclone chamber provided in the air flow path and comprising a cyclone air inlet, a cyclone air outlet, a cyclone dirt outlet and a cyclone chamber wall; (c) a dirt collection chamber comprising a first end, a spaced apart opposed second end, a dirt inlet in communication with the cyclone dirt outlet, an annular portion that surrounds at least a portion of the cyclone chamber, an inner side adjacent the cyclone chamber, and an outer side spaced from the cyclone chamber and defined by a dirt collection chamber sidewall; and, (d) a support surface extending between the inner side and the outer side, configured to direct dirt towards a dirt collection area of the dirt collection chamber.
 2. The surface cleaning apparatus of claim 1 wherein the support surface extends part way around the annular portion and extends away from the dirt inlet.
 3. The surface cleaning apparatus of claim 1 wherein the support surface has first and second ends that are angularly spaced apart around the cyclone chamber and the support surface extends continuously away from the dirt inlet from the first end to the second end.
 4. The surface cleaning apparatus of claim 1 wherein the support surface has first and second ends that are angularly spaced apart around the cyclone chamber and a mid-section and the support surface extends continuously away from the dirt inlet from the mid-section to the first end and to the second end.
 5. The surface cleaning apparatus of claim 1 wherein the support surface is curved.
 6. The surface cleaning apparatus of claim 1 wherein the support surface has first and second ends that are angularly spaced apart around the cyclone chamber and the support surface extends towards the dirt inlet from the first and second ends at an angle of up to 50° from a plane transverse to a longitudinal axis of the cyclone chamber.
 7. The surface cleaning apparatus of claim 6 wherein the support surface extends towards the dirt inlet from the first and second ends at an angle from to 15° to 35° from a plane transverse to a longitudinal axis of the cyclone chamber.
 8. The surface cleaning apparatus of claim 1 wherein the dirt inlet is provided at the first end and the support surface is spaced from the dirt inlet towards the opposed second end.
 9. The surface cleaning apparatus of claim 8 wherein the cyclone dirt outlet is the dirt collection chamber dirt inlet.
 10. The surface cleaning apparatus of claim 1 wherein the dirt collection chamber comprises the dirt collection area is provided at the opposed second end.
 11. The surface cleaning apparatus of claim 10 wherein the dirt inlet is at an upper end of the dirt collection chamber and the dirt collection area is in a lower portion of the dirt collection chamber.
 12. The surface cleaning apparatus of claim 1 wherein the cyclone chamber and the dirt collection chamber are provided in a cyclone bin assembly and the cyclone bin assembly is removably mounted to the surface cleaning apparatus.
 13. The surface cleaning apparatus of claim 1 wherein the cyclone chamber has a cyclone chamber first end and an opposed cyclone chamber second end and the cyclone dirt outlet is provided adjacent the cyclone chamber first end and the cyclone air inlet is provided at the opposed cyclone chamber second end.
 14. The surface cleaning apparatus of claim 13 wherein cyclone chamber air outlet is provided at the opposed cyclone chamber second end.
 15. The surface cleaning apparatus of claim 13 wherein the cyclone chamber first end is an upper end of the cyclone chamber.
 16. The surface cleaning apparatus of claim 13 wherein the cyclone chamber first end is provided proximate the first end of the dirt collection chamber.
 17. The surface cleaning apparatus of claim 1 wherein the cyclone chamber has a cyclone chamber first end and an opposed cyclone chamber second end and the cyclone chamber is provided proximate the first end of the dirt collection chamber and the opposed second end of the dirt collection chamber is spaced from and faces the opposed cyclone chamber second end.
 18. The surface cleaning apparatus of claim 1 wherein air travels in the annular portion in a direction of rotation and the support surface extends away from the dirt inlet in the direction of rotation.
 19. The surface cleaning apparatus of claim 18 wherein the support surface has first and second ends that are angularly spaced apart around the cyclone chamber and the support surface extends continuously away from the dirt inlet from the first end to the second end. 